SERVICE MANUAL - bigjoesupport.com

1 Big Lift LLC - NO. BL-E25-LPT26- SERVICE -0717 - 07-15-E25/LPT26 SELF-PROPELLED, PALLET LIFT Patents Nos. 9,879,765; D801,616; D805,712; D805,713 SERVICE MANUALWARNINGDo not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator s MANUAL and on not operate this truck until you have checked itscondition. Give special attention to wheels, horn, bat-tery, controller, lift system, brakes, steering mecha-nism, guards and safety truck only from designated operating not carry passengers. Keep feet clear of truck andwear foot applicable traffic regulations. Yield right ofway to pedestrians.

2 Slow down and sound horn atcross aisles and wherever vision is , stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of over-turning may be look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with special care when operating on ramps travelslowly, and do not angle or turn. Travel with not handle loads which are higher than the chassisunless load is secured so that no part of it could fallbackward. Before lifting, be sure load is centered,forks are completely under the chassis leaving the truck, neutralize travel control, fullylower lifting mechanism and set brake.

3 When leavingthe truck unattended, also shut off OF CONTENTSBL-E25-LPT26- SERVICE -0717 - 07-15-2020 SectionPageSectionPageINFORMATION & TOOLS USED FOR SERVICE ..3 GENERAL TIGHTENING MAINTENANCE AND INSPECTIONS ..5 OVERVIEW .. OPERATIONS AND FUNCTIONS ..13 OPERATIONS & SWITCH ..13 EMERGENCY REVERSE SWITCH ..13 HORN PANEL ..14 KEY SWITCH ..14 EMERGENCY STOP ..14 CONTROLLER ..15 LIFTING LIMIT PUMP ..15 PUMP WHEEL ..17 REMOVAL AND AND AND ROD ADJUSTMENT ..18 REMOVAL AND DRIVE ASSEMBLY ..21 REMOVAL AND AND AND AND CIRCUIT TROUBLESHOOTING AND AND MOTOR ..26 REMOVAL AND AND AND AND AND OPERATING SWITCH.

4 30 REMOVAL AND INSTALLATION ..30 FAULTS AND AND CIRCUIT AND INSTALLATION ..32 FAULTS AND AND CIRCUIT TROUBLESHOOTING 32 HYDRAULIC SYSTEM .. SCHEMATIC DIAGRAM ..33 PUMP AND MOTOR ASSEMBLY ..34 REMOVAL AND INSTALLATION ..34 COMPONENTS ..34 PUMP MOTOR ..35 REMOVAL AND INSTALLATION ..35 FAULTS AND AND AND INSTALLATION ..36 FAULTS AND AND CIRCUIT TROUBLESHOOTING 37 LIFT REMOVAL PRECAUTIONS ..38 CYLINDER INSTALLATION PRECAUTIONS ..38 REMOVAL AND INSTALLATION ..39 HYDRAULIC TROUBLESHOOTING ..41 HYDRAULIC SYMBOL ..42 ELECTRICAL AND INSTALLATION REMOVAL43 CONTROLLER INTERFACE FUNCTION TRACTION CONTROLLER (1212C) ..43 KEY AND INSTALLATION ..45 FAULTS AND AND CIRCUIT TROUBLESHOOTING STOP AND INSTALLATION.

5 46 FAULTS AND AND CIRCUIT TROUBLESHOOTING 46 INDUCTIVE AND INSTALLATION ..47 FAULTS AND AND CIRCUIT TROUBLESHOOTING OF CONTENTS - ContinuedBL-E25-LPT26- SERVICE -0717 - 07-15-2020 REMOVAL AND INSTALLATION .. 49 SectionPageSectionPageFAULTS AND 50 CHECKING AND 50 CONTROL CIRCUIT TROUBLESHOOTING BATTERY .. 50 FAULTS AND 50 CHECKING AND 52 HANDHELD UNIT (OPTIONAL) .. 54 HANDHELD UNIT 54 HANDHELD UNIT MAIN MENU .. 54 MONITOR 55 CONTROLLER ERROR 56 TRACTION CONTROLLER .. 57 ELECTRICAL SCHEMATIC 61 CABLE WIRING DIAGRAMS ..62 WIRING HARNESS AND TROUBLESHOOTING ..65 BEFORE THE VOLTAGE OF BATTERY ..65 TROUBLESHOOTING COMMON LITHIUM-ION AND WARNINGS.

6 69 USE OF ..69 CHARGING ..69 MAINTENANCE & OPERATORS OF CONTENTS - ContinuedBL-E25-LPT26- SERVICE -0717 - 07-15-2020 NOTESBL-E25-LPT26- SERVICE -0717 - 07-15-20201 SAFETY WARNINGFor your own safety and that of others, please observethe following safety instructions:Thorough scheduled maintenance is one of the mostimportant prerequisites to ensure stable and reliableoperation of truck. Neglecting regular maintenancecould easily lead to the truck malfunctioning and failure,and potential threats to staff and operational , there must be adequate maintenance,professional trained technician and a comprehensivemaintenance plan in perform the maintenance and inspectionsaccording to the following provisions:1.

7 To strictly enforce the truck maintenance, lubrica-tion and inspection following operations shall be performedbefore you leave the truck:- No parking on Fully lower the Cut off the power- Turn the Key switch to STOP positionand remove the Prior to truck maintenance:- Raise the drive wheel off the ground,remove the power Use blocks or stands when performingmaintenance underneath the vehicle,make sure that the lifting device or jackleg is Park your vehicle in a safe and Never use an open flame to check level of oils orfluids Keep the charging area clean, well-ventilated Regular operational checks and maintenanceshould be conducted to braking, steering, control.

8 Warning and safety devices to keep them in goodoperating All data plates and safety signs on the truckshould be cleaned regularly to make them Regular checks and maintenance should be con-ducted on the lifting system to ensure they aresafe for hydraulic system should be checked on aregular basis. Hydraulic cylinders, hydraulicvalves and other hydraulic components should beinspected for Regular checks and maintenance should be con-ducted to batteries, motors, controllers, limitswitches, safety devices, wires and pay particular attention to the electricalinsulation on the cables and wire Park the truck in a clean environment to minimizethe risk of Users are not allowed to change or increasethe capacity of the - 07-15-2020 SECTION 1 INFORMATION & SPECIFICATIONS1-1.

9 TRUCK OVERVIEWF igure 1-1 E25/LPT26 Lift TruckTable 1-1 E25/LPT26 Lift Truck ComponentsWarning:Please refer to the data plate for the load capacity of the truck can only be used on the level ground indoors, never use it on mezzanine or balcony truck should only be operated by authorized #DescriptionPos. #Description1 Control Head6 Battery2 Key Switch7 Drive Wheel3 Emergency Stop Switch8 Drive Unit Cover4 Front guard9 Pump and Motor Assembly5 Fork10 Lift CylinderBL-E25-LPT26- SERVICE -0717 - 07-15-202031-2. COMMON TOOLS USED FOR SERVICET able 1-2 Common Tools1-3. GENERAL TIGHTENING TORQUESS crews or bolts used on the truck are of grade orhigher performance you are conducting truck maintenance, you canrefer to Table 1-3 and Table 1-4 to select the suitablescrews or bolts for 1-3 Screws/Bolts Performance LevelsCaution.

10 The performance levels of screws or bolts are marked on the heads of the screws or you find the screws or bolts used on certain position are not marked with performance level,please select spare parts with performance level of at least grade or higher level for Hex Wrench2#~6# One Set2 Hex Head Socket Wrench8#~19# One Set3 Phillips Screwdriver2# One Piece4 Slotted Screwdriver2# One Piece5 Snap Ring PliersOne for holes and one for shaft6 HammerOne Piece7 Lifting StrapOne Pair8 WIre CuttersOne Pair9 Grease GunOne Piece10 Box Wrench22mm/27mm One of EachPerformance LevelMaterialSpecification (mm) grade Low carbon steelM6 ~ gradeQuenched and tempered medium carbon steelM6 ~ gradeQuenched and tempered medium carbon alloy steelM6 ~ gradeQuenched and tempered medium carbon alloy steelM6 ~ M484BL-E25-LPT26- SERVICE -0717 - 07-15-2020 Table 1-4 Metric Screws/Bolts Tightening Torque Table (n m)Nominal Diameter (mm)Performance Stress (MPa)